Concrete fillable formwork wall

ABSTRACT

A formwork assembly is adapted to receive concrete to produce structures such as wall structures. The formwork includes PVC tubular form elements having recessed female engagement portions. The female engagement portions are adapted to receive respective male engagement portions. An octagonal form element has a female engagement portion positioned at each vertex between adjacent sides. A recessed female engagement portion is closed to the interior of the form element but open to the exterior of the form element. Thus, the form element includes a plurality of vertices open to the exterior. The form elements also include male engagement portions at an open side. Wall panels, corner panels, and joint connectors can also include male engagement portions. The male engagement portions and female engagement portions are adapted to mate to form a formwork arrangement having a substantially flat exterior wall. A formwork assembly can additionally include concrete flow apertures and insulation

TECHNICAL FIELD

This invention relates to formwork adapted for use in casting concretestructures. The invention also involves a method of arranginginterconnectable formwork elements in forming a formwork. Particularly,this invention relates to interconnectable formwork elements adapted foruse in forming concrete walls with flat surfaces.

BACKGROUND OF THE INVENTION

The use of form elements which interconnect to form a wall structureinto which concrete can be poured is known. The prior art formworkassemblies often result in arrangements that preclude a principlesurface from being flat. In some formwork assemblies the desiredpattern, such as flat surfaces at corners, is unobtainable due to theformwork engagement portions or connections available. That is, the formelements and their connections can be unarrangeable to achieve aformwork with a flat surface. In other formwork assemblies the pressureof poured concrete often results in the surface bulging due to lack ofstrength in the formwork element connections. Still other, formworkassemblies are complicated and difficult to assemble and/or add internalcomponents such as insulation, rebar, etc., which can result in loss oftime and assembly errors, such as misalignment of wall surfaces.Further, during assembly some formwork arrangements can require innerbraces to be inserted into a formwork element subsequent to the formworkelement being connected to another formwork element.

Further drawbacks in the prior art involve the use of engagementportions or fins which extend outwardly from a form element body.Difficulties can arise from such form elements, such as in nesting forshipping, manually handling, snagging during assembly, as well as theoverall aesthetics issue of having exterior engagement portions. Theseexternal engagement fins can also interfere with the formation of a flatsurface.

The prior art formwork assemblies can lead to quality control problems,especially when stringent construction specifications are required.Other problems can also arise due to required length of assembly timeand difficulty of assembly. Additionally, since errors in assembly maynot be noticeable until the formwork is nearly completed, difficulty inrearranging prior art formworks can cause delays and increase costs.

DISCLOSURE OF THE INVENTION

Thus, there exists a need in the art for a formwork for casting concretestructures which enjoys ease and quickness of assembly, can result in aflat surface, and can be easily modified once assembled to allow on-sitealterations. Such a formwork, and its assembly, would also contribute toalleviating the problems of the prior art.

An aspect of an exemplary form of the present invention is to provide aformwork arrangement having interconnectable form work components.

A further aspect of an exemplary form of the present invention is toprovide a formwork adapted for use in casting concrete structures, suchas a concrete wall.

A further aspect of an exemplary form of the present invention is toprovide a formwork form element with recessed female engagementportions.

A further aspect of an exemplary form of the present invention is toprovide a form element with extending male engagement portions.

A further aspect of an exemplary form of the present invention is toprovide a form element with both recessed female engagement portions andextending male engagement portions.

A further aspect of an exemplary form of the present invention is toprovide a form element with male engagement portions which are adaptedto engage corresponding respective female engagement portions of anotherform element.

A further aspect of an exemplary form of the present invention is toprovide a form element of tubular configuration with an open end.

A further aspect of an exemplary form of the present invention is toprovide a form element with male engagement portions, adjacent an openend, which are adapted to engage corresponding respective femaleengagement portions of another form element.

A further aspect of an exemplary form of the present invention is toprovide a formwork with wall panels and/or corner panels that includemale engagement portions.

A further aspect of an exemplary form of the present invention is toprovide a formwork with wall panels and/or corner panels having maleportions adapted to engage corresponding female portions of a form unitresulting in a substantially flat wall surface.

A further aspect of an exemplary form of the present invention is toprovide a formwork arrangement which includes apertures permittingconcrete to freely flow between adjacent formwork chambers.

A further aspect of the present invention is to provide a formworkarrangement which permits ease of rebar installations.

A further aspect of the present invention is to provide a formworkarrangement which permits ease of modification after assembly A furtheraspect of an exemplary form of the present invention is to provide aformwork arrangement with apertures in form elements and/or panels so asto permit concrete to cross flow into formwork chambers.

A further aspect of an exemplary form of the present invention is toprovide a formwork that is easy to clean, does not burn, has anattractive appearance, is reflective, is chemical resistant, is of highstrength, and/or does not require components below grade. A furtheraspect of an exemplary form of the present invention is to provide aformwork that is adapted for use in any residential or nonresidentialstructure. A nonresidential structure can be an agriculture facility,such as a hog barn or in a storage structure for agriculture wastes.

A further aspect of an exemplary form of the present invention is toprovide a formwork that is adapted for use in a cleaning facility, suchas in an auto wash structure or other facility that needs regularcleaning for regulatory reasons.

Further aspects of exemplary forms of the present invention will be madeapparent in the following Embodiments of Invention and the appendedClaims.

The foregoing aspects are accomplished in an exemplary embodiment of thepresent invention by the use of interconnectable formwork components.

The formwork components can be assembled to form a formwork assembly inwhich concrete can be held to form a substantially flat surface, eitheran entire wall or a portion thereof. Male portions of a wall panel canbe connected to respective female portions of adjacent tubular formelements. Male portions of a corner panel can be connected to respectivefemale portions of a tubular form element. A connection arrangement oftubular form elements, wall panels, corner panels, and joint connectorscan permit an alignment resulting in a substantially flat wallconfiguration.

Flow apertures in formwork components, such as tubular form elements,can permit poured concrete to cross flow through the form elementsresulting in an even dispersion of concrete and a quicker casting time.

Some embodiments can use material, apertures, arrangements, andorientations disclosed in U.S. Pat. No. 5,216,863, the disclosure ofwhich is incorporated herein by reference.

Thus, a formwork of the exemplary embodiment can include tubular formelements capable of receiving concrete to form a wall structure. Theformwork can include a PVC or other polymeric form element with a femaleengagement portion positioned at each joint between two adjacent walls.The female engagement portions are closed to the interior of the formelement but open to the exterior of the form element. That is, the formelement includes open vertices. The form elements each include an openlongitudinal side and male engagement portions adjacent thereto. Themale engagement portions can extend radially outwardly from theirrespective form element adjacent the open side.

The formwork can include other formwork connecting members adapted tointerconnect the form elements and create a substantially flat exteriorwall surface. These other formwork connecting members can include wallpanels, corner panels, external joint connectors, and internal jointconnectors, with a desirable feature being that such members are modularfor efficient design and convenient assembly.

For example, a preferred geometry for such members is a regular geometrypermitting symmetric design and construction. Of the regular geometricforms, a regular octagon is preferred. Regular geometric forms in evenmultiples are also possible. Moreover, the members can haveinterconnectivity with other non-modular frameworks. Each of theformwork components, e.g., form elements, wall panels, corner panels,external joint connectors, and internal joint connectors can be of anintegral or one-piece construction.

Furthermore, each of the formwork components can be molded and/orextruded. Additionally, the formwork components can use male/femaleengagement relationships that permit identification of common loci ofeach connection with the placement of each locus at the vertices of aregular geometric form.

The exemplary wall panels have an integral substantially flat wallsurface with a male engagement portion at each end. Both male engagementportions extend from the same side of the wall surface. Each maleengagement portion has a first projection and an integral secondprojection. The first projections extend substantially parallel to thewall surface and each other, and the second projections extend towardeach other. The second projections can extend substantiallyperpendicular.

The exemplary corner panels have two integrally joined substantiallyperpendicular and substantially flat wall surfaces with two free ends.Both free ends include a male engagement portion. Both male engagementportions extend from the same (inner or outer) side of the corner. Eachmale engagement portion has a first projection and an integral secondprojection. The first projections extend substantially parallel to theirrespective wall surface and perpendicular to each other, and the secondprojections extend parallel to each other. The second projections canfurther extend toward each other.

The exemplary external joint connectors include both a male engagementportion and a female engagement portion integrally connected by a commonelongated member.

The exemplary internal joint connectors include two integrally connectedmale engagement portions. In cross section each male engagement portionextends on both sides of an integral common elongated member. Each maleengagement portion has a first projection and an integral secondprojection. The first projections are parallel and the secondprojections extend away from each other.

During assembly of an exemplary embodiment the male engagement portionsand female engagement portions of particular form elements, wall panels,corner panels, external joint connectors, and internal joint connectorscan be mated to form a formwork having a substantially flat exteriorwall surface.

BRIEF DESCRIPTION OF DRAWINGS

FIG. 1 shows a form element of an exemplary embodiment of the presentinvention.

FIG. 2 shows a female engagement portion in combination with thebeginning of adjoining wall portions.

FIG. 3 shows a male engagement portion in combination with the beginningof an adjoining wall portion.

FIG. 4 shows a male portion in operative engagement with a femaleportion.

FIG. 5 shows an exemplary formwork section having an arrangement ofengaged form elements.

FIG. 6 shows an exemplary wall panel.

FIG. 7 shows an exemplary formwork section having engaged form elementswith a wall panel.

FIG. 8 shows an exemplary formwork section having engaged form elementswith wall panels on opposite walls.

FIG. 9 shows an exemplary corner panel.

FIG. 10 shows an alternative corner panel.

FIG. 11 shows an exemplary formwork section having the corner panels ofFIGS. 9 and 10.

FIG. 12 shows an exemplary external joint connector.

FIG. 13 shows an exemplary internal joint connector.

FIG. 14 shows an exemplary formwork section having an external jointconnector and an internal joint connector.

FIG. 15 shows an exemplary elongated form element.

FIG. 16 shows an exemplary octagonal elongated form element with theoutline of two octagonal regular form elements.

FIG. 17 shows an angled view of a cut away portion of an exemplaryformwork arrangement.

FIG. 18 shows an exemplary formwork section having form elements,elongated form elements, external joint connectors, and internal jointconnectors.

FIG. 19 shows an exemplary buck panel adapted for engagement with a formelement.

FIG. 20 shows an exemplary buck panel adapted for engagement with anelongated form element or with two form elements. FIGS. 21-24 showvarious cut away portions of exemplary buck panels connected torespective form elements.

FIG. 25 shows an exemplary form element with a closed vertex.

FIG. 26 shows an exemplary elongated form element absent a femaleportion at a wall.

FIG. 27 shows an exemplary form element having a female portion closedto the exterior but open to the interior.

FIG. 28 shows an exemplary form element with a closed female portioninoperative to receive a male portion.

FIG. 29 shows an example of a closed female portion on a wall of anelongated form element.

FIG. 30 shows another example of a closed female portion on a wall of anelongated form element.

FIG. 31 shows a further example of a closed female portion on a wall ofan elongated form element.

FIGS. 32-33 show a comparison of exemplary wall panels having similarconfiguration but different lengths.

FIG. 34 shows an example of male engagement portion configurations of awall panel.

FIG. 35 shows another example of male engagement portion configurationsof a wall panel.

FIG. 36 shows an example of a wall panel with a male engagement portionhaving an alternative configuration.

FIG. 37 shows a further example of a wall panel with a male engagementportion having an alternative configuration.

FIG. 38 shows an example of a corner panel with a male engagementportion having an alternative configuration.

FIG. 39 shows a further example of a corner panel with a male engagementportion having an alternative configuration.

FIG. 40 shows an example of a form element having all sides closed.

FIGS. 41-55 show examples of form elements having various aperturearrangements on form element wall portions.

FIGS. 56 and 57 show examples of formwork sections containinginsulation.

FIGS. 58 and 59 show further examples of formwork sections containinginsulation.

FIG. 60 shows a formwork curvature arrangement.

FIG. 61 shows another formwork curvature arrangement.

FIG. 62 shows an exemplary agriculture facility holding structure.

FIG. 63 shows an example of a formwork section having apertures.

FIG. 64 shows a formwork section having a filled portion and a hollowportion.

FIG. 65 shows an angled view of exemplary form elements and a drainagesystem.

FIG. 66 shows an exemplary agriculture facility storage arrangement.

FIG. 67 shows an exemplary vehicle wash facility.

FIG. 68 shows an example of a formwork having a differential elevationarrangement.

FIG. 69 shows another example of a formwork having a differentialelevation arrangement.

FIGS. 70 and 71 show exemplary form element aperture patterns.

FIGS. 72 and 73 show exemplary elongated form element aperture patterns.

FIG. 74 shows an example of a formwork wall with alignment saddles.

FIG. 75 is a side view of the arrangement of FIG. 74.

FIG. 76 shows another example of a formwork wall with alignment saddles.

FIG. 77 is a side view of the arrangement of FIG. 76.

EMBODIMENTS OF INVENTION.

An exemplary formwork of the present invention can include a formelement or unit (10) having a tubular structure. A tubular form elementis adapted to contain concrete as discussed in more detail later. A formelement in longitudinal cross section can be circular, oval, polygonal,octagonal, sixteen edged, rectangular, and other tubular shapes. Forreasons of brevity, an octagonal shaped form element is discussed indetail herein. However, it should be understood that the presentinvention is not limited to use with an octagonal form element but thatother form element cross sections can be used.

FIG. 1 shows a form element of an exemplary embodiment of the presentinvention. A form element 10 of octagonal shape is shown in theexemplary embodiment of FIG. 1. The octagonal form element 10 includeseight vertices 12 of substantially equal spacing. The form element 10 iselongated longitudinally. The form element includes an elongatedlongitudinal interior chamber 13. The form element of FIG. 1 alsoincludes seven walls or faces 14 and one elongated open face, end, orside 16. In FIG. 1 the walls are substantially of equal length andpositioned at substantially equal angles forming a substantiallyC-shaped form element in cross section. However, it should be understoodthat in other exemplary embodiments a form element can have walls not ofsubstantially equal length and positioned not at substantially equalangles. Also, a form element can include other shapes in cross section,such as without an open end, circular, or O-shaped. For example, anoctagonal form element can have eight walls without an open face.

The form element 10 can include a respective female engagement portionor member 18 at one or more joinings (e.g., vertex or corner) of twoadjacent faces. For example, the form element 10 of FIG. 1 is shown withsix respective female engagement portions.

An exemplary embodiment of a female engagement portion 18 is shown inFIG. 2. FIG. 2 shows a female engagement portion in combination with thebeginning of adjoining wall portions. A female engagement portion cancomprise a slot, groove, indentation, recess, pocket, opening, or othersimilar engagement structure. The female engagement portion is of ashape permitting mating engagement with a corresponding male engagementmember. For example, a female engagement portion can comprise a T-shapedslot in cross section. Of course a female engagement portion can haveother alternative configurations, such as P-shaped or H-shaped orY-shaped. The female engagement portions can extend the entire verticallength or only a partial length of the formwork. Each female engagementportion can be located internally of an exterior boundary of the formelement. For example, with an octagonal form element, the femaleengagement portions can be located internally of an exterior octagonalboundary of the octagonal form element.

Each female engagement portion 18 is adapted to mate with a respectivemale engagement portion or member. A form element 10 can include bothfemale engagement portions and male engagement portions. An exemplaryembodiment of a male engagement portion 20 is shown in FIG. 3. FIG. 3shows a male engagement portion in combination with the beginning of anadjoining wall portion. A male engagement portion can comprise one ormore of an engagement fin, projection, finger, lip, or other similarengagement structure. A male engagement portion is of a shape permittingmating engagement with a corresponding female engagement member. Forexample, a male engagement portion can comprise a T-shaped fin. TheT-shaped fin is adapted to engage a T-shaped slot (or a slot of a shapepermitting engagement with a T-shaped fin). Of course a male engagementportion can have other alternative configurations, such as P-shaped orH-shaped or Y-shaped. The male/female engagement relationships permitidentification of common loci of each connection with the placement ofeach locus at the vertices of a regular octagon.

An engagement arrangement permits male and female loci to fall on avertex of a form element. Vertices of a form element can exist at anintersection of extended adjacent outer edges of a form element. Asshown in FIG. 2, an intersection point is indicated by the mark “x”.That is, the locus of a female portion can be indicated by the mark “x”in FIG. 2. The locus of a male portion can be indicated by the mark “x”in FIG. 3. When a male and a female portion are in engaged relationship,then the male portion locus and the female portion locus can commonlymeet or overlap at a vertex of a form element. That is, the male andfemale portions can share a common locus during their engagement orconnection. FIG. 4 shows a male portion 20 in operative engagement orconnection with a female portion 18. FIG. 4 shows an example of thepermitted commonality of each male and female locus. The male/femaleengagement relationships can permit the placing of common loci from eachconnection at each of the vertices of the form elements in a formworkassembly. Thus, a formwork assembly can be truly modular.

FIG. 1 shows a form element 10 having two male engagement portions 20adjacent the open face 16. Each male portion can be arranged to extendoutside of the exterior boundary of a form element. For example, eachmale portion can extend outside of the exterior octagonal boundary of anoctagonal form element. Thus, a male portion 20 of a first form elementis adapted to engage a female portion 18 of an adjacent second formelement to engage, interconnect, or lock together the two form elements.FIG. 4 shows an engagement relationship of a male portion 20 and afemale portion 18.

In a form element, each of the walls, female portions, and male portionscan be integral. The form element can be of a one piece construction.For example, the form element can be of a molded and/or extrudedstructure.

A form element can have all of the inward extending female portions ofthe same configuration and all of the outward extending male portions ofthe same configuration. However, it should be understood that a formelement need not have the same engagement configurations. For example,the female portions of a particular form element can differ from eachother. Likewise, the male portions of a particular form element candiffer from each other. Nor do the male portions on a form element haveto match the female portions on that same form element. Further, theformwork can include some form elements having all corresponding maleand female portions and other form elements having all alternativecorresponding male and female portions. Still, other formworks can havevarying corresponding male and female portions. Even with varyingconfigurations, each respective male portion is adapted to be aligned tomatch a corresponding respective female portion to permit engagement,interconnection, or locking of the male and female portions duringassembly.

Various types of assembly processes can be used to result in engagementof male and female portions. For example, male and female portions canbe respectively engaged to each other by sliding engagement. That is, amale portion can slide into and relative to a female portion, and/or afemale portion can slide outside of and relative to a male portion. Thesliding can occur over the entire length, such as the height, of aportion. For example, during assembly a male portion can be slid insideof a female portion in a direction parallel to and along a longitudinalaxis of the female portion. Other types of assembly processes can beused, such as one including a snap-fit type of engagement. For example,during a snap-fit assembly a male portion can be relatively moved into afemale portion in a direction perpendicular to a longitudinal axis ofthe female portion. Still other assembly processes can include movementof a male portion both perpendicular and parallel to a longitudinal axisof a female portion. For example, a female portion can comprise alongitudinal extending pocket with vertically spaced horizontal slotsthereto which permit a male portion to be moved perpendicularly into thefemale portion and then moved parallel along the female portion to afinal assembly position.

The arrangement of a form element 10 permits the internalization of theengagement points. That is, engagement of male and female portions canoccur internally of the exterior boundary of a form element. This allowsall external side surfaces, such as walls 14, of the form element to liewithin a plane for creation of a flat surface arrangement.

FIG. 5 shows a formwork arrangement 21 of engaged form elements 10. Thearrangement permits the production of corners and intersections withoutprojections extending beyond a flat wall surface 14 of a form element10. FIG. 5 also shows the engagement of male portions 20 of a first formelement 10 respectively engaging female portions 18 of an adjacentsecond form element 10.

An exemplary embodiment of the present invention also includes use of apanel which is adapted to engage at least one female engagement portionof a form element for use in forming an arrangement having asubstantially flat wall. FIG. 6 shows a flat panel insert or wall panel22. The wall panel 22 can be separate or distinct from a form element.The wall panel has at least one end 25 with a male engagement portion26. The male engagement portion 26 can be of similar configuration andoperation as the previously discussed male engagement portions. Like thepreviously discussed male engagement portions, the male engagementportion 26 can comprise one or more of an engagement fin, projection,finger, or lip 28. Of course other alternative configurations and sizesof wall panels and/or male portions can be used, such as shown in FIGS.32-37. A male engagement portion is adapted to engage a matching femaleengagement portion. FIG. 6 shows each end of wall panel 22 havingidentical male end engagement portions 26. The male engagement portions26 of FIG. 6 are adapted to engage two female engagement portions ofadjacent form elements.

The wall panel 22 of FIG. 6 includes a substantially straight or flatsurface. As shown in FIG. 7, a panel 22 permits the parallel but spacedfaces 14 of two adjacent form elements 10 to be connected or engaged inparallel relationship. Thus, the wall panel 22 can be used in forming asubstantially flat wall including at least the two faces and the wallpanel. A completed flat wall of a formwork can include severalalternating form element faces and wall panels. A wall panel 22 can alsobe used to close an open cross-sectional triangular open space or area24 created between two engaged form elements as shown in FIG. 7. Theclosed area 24 can remain an open channel or be operative to holdconcrete or insulation. Additionally, the area 24 can be used forservice items, such as wiring or plumbing. The area 24 can also be usedas a fluid, such as air, conveying mechanism. A wall panel 22 can alsohave insulation directly adhered to an interior side thereof. Forexample, the insulation can be attached using an adhesive or theinsulation can be snap-fitted onto a wall panel projection. One or morelayers of insulation can be applied using a LEGO® block type ofattachment arrangement. Examples of insulation are shown in FIGS. 56-59.In an exemplary embodiment, insulation can be placed between horizontalrebar and forced into a final position by the pressure of pouredconcrete. Attachment of insulation prior to wall assembly can result ina decrease in assembly time. Of course insulation can also be attachedto other formwork components (e.g., form elements and panels) in asimilar manner. Additionally, insulation can be fastened, such as byadhering, to the outside of a formwork wall section. The insulation canthen be covered or hidden by traditional finishing techniques, such assiding, brick, etc.

It should be understood that the use of “substantially flat wall” hereinincludes not only a perfectly flat wall but an imperfect flat wall withreasonable deviations due to imperfections, misalignments, seams, andother factors, such as temperature, pressure, size, and age. Forconvenience the terms “flat wall” and “substantially flat wall” can beinterchanged herein. Furthermore, “flat” can comprise planer. A flatwall can also comprise all surfaces lying within the same plane,including a cylindrical plane.

FIG. 8 shows wall panels 22 on two opposite sides of plural engaged formelements 10. Thus, two (e.g., interior and exterior) substantially flatand parallel wall surfaces can be formed for a concrete wall structureby using form elements and wall panels.

FIGS. 9 and 10 show other insert panels which are adapted to engage atleast one female engagement portion of a form element for use in formingan arrangement having a flat wall. FIG. 9 shows a corner panel 30adapted to engage two female engagement portions of a single formelement. The corner insert panel 30 can be separate or distinct from aform element. The panel 30 has at least one end 32 with a maleengagement portion 34. The male engagement portion 34 can be of similarconfiguration and operation as the previously discussed male engagementportions. Thus, the male engagement portion 34 can comprise one or moreof an engagement fin, projection, finger, or lip 38. Of course a maleengagement portion of panel 30 can have other alternativeconfigurations. FIG. 9 shows each end of corner panel 30 having anidentical male end engagement portion 34. The male engagement portions34 are adapted to engage respective matching female engagement portions,such as those of a form element.

The corner panel 30 of FIG. 9 includes substantially perpendicular wallsurfaces. The panel 30 permits the forming of flat corners. As shown inFIG. 11, the corner panel 30 permits the attachment of a corner portionto a form element 10 resulting in the extension of substantiallyperpendicular and substantially flat walls 40, 42. As shown in FIG. 11,the panel 30 can be used in forming the exterior of a formwork cornerportion.

A corner panel can have other geometric shapes, such as a curvilinearwall surface or angled wall surfaces other than ninety degrees (e.g., atforty-five degrees).

FIG. 10 shows a corner panel 44 similar to corner panel 30. However, thecorner panel 44 is adapted to engage two female engagement portions ofadjacent form elements. The corner panel 44 has at least one end 46 witha male engagement portion 48 extending differently than the maleengagement portion 34 of corner panel 30. In FIG. 10 the male engagementportion 48 is rotated approximate 180 degrees relative to the maleengagement portion 34 of corner panel 30. The male engagement portion 48can be of similar configuration and operation as the previouslydiscussed male engagement portions. Thus, the male engagement portion 48can comprise one or more of an engagement fin, projection, finger, orlip 50. FIG. 10 shows each end of corner panel 44 having identical maleend engagement portions 48. The male engagement portions 48 are adaptedto engage respective matching female engagement portions, such as thoseof a form element. As shown in FIG. 11, the corner panel 44 permits theattachment of a corner portion resulting in the extension ofsubstantially perpendicular and substantially flat walls 52, 54. Asshown in FIG. 11, the corner panel 44 can be used in forming an interiorsurface of a formwork corner portion.

An exemplary form of a formwork of the present invention can haveidentical male engagement portions with a common connection locus.Female engagement portions can likewise be identical and have a commonlocus.

Of course it should be understood that the male end engagement portionsof respective wall panels and corner panels do not have to be identicalbut can have different male configurations. That is, the configurationsof the male end engagement portions on a single wall panel can differ.Likewise, the configurations of the male end engagement portions on asingle corner panel can also differ.

It should also be understood that the sizes (e.g., length, width, depth,etc.) of wall panels and corner panels can vary. That is, a formworkarrangement can include wall panels of different sizes and corner panelsof different sizes.

Also, it should be understood that the surfaces of wall panels andcorner panels (and form elements) can be corrugated. Corrugation can beused to increase strength and/or flexibility. Other shapes can includerolled, stippled, curved, etc. Additionally, a formwork wall arrangementcan have a custom shape. For example, a formwork wall arrangement can beflat on one side and corrugated on the other side. A wall structure canalso be planar but the outer surface used can architecturally lookrolled, corrugated, stippled, curved, etc.

A formwork profile can also be arranged to allow reduction in externalhydrostatic pressure, such as in a below ground grade structure.Perforations 56, holes, openings, apertures, or similar structure can beprovided in one or more panels (e.g., wall panels and/or corner panelsand/or form elements). A formwork space or void or channel 57, 58adjacent to and interior of an exterior panel, as shown in FIG. 11, canbe fluidly connected to a drainage system. For example, such anarrangement can be used to remove water adjacent to a formwork wallstructure. Water would be permitted to enter panel perforations, flowdownward inside the void toward a footer, and then be drained away fromthe wall structure by the drainage system. Such an arrangement can alsoprotect from moisture products that can be stored inside of an enclosurehaving the perforated wall structure. An arrangement using perforationscan also be used to provide continual air and/or water vapor flowthrough any of the void spaces, such as in vegetable storage facilities.Void spaces defined by adjoining form elements and a wall panel or acorner panel can serve as a conduit of fluid ingress or egress toprovide air, moisture, or other fluid into or out of a structure'sinterior. For example, certain crops such as potatoes may requireairflow to prevent spoilage. Any of such void spaces can be connected toa forced-air system to cause airflow from the spaces into the interiorspace. Alternatively, void spaces adjoining the exterior of thestructure can have perforations to permit equilibration of hydrostaticpressures between the exterior and the interior of the structure.

Other formwork arrangements can be used with products to provide longterm assurance of a substantially dry internal environment. For example,a TPE seal or other water proofing systems and/or sealers can be used tokeep out water. The exterior walls of a concrete filled formworkstructure can include water absorbing products, such as bentonite,therein or as a separate layer thereon.

Other exemplary forms of formwork arrangements can have increasedconcrete strength through retaining the water of hydration. Formworkarrangements can also permit use of high flow concrete to reduceconstruction costs. It should also be understood that a formwork of thepresent invention is not limited to use with concrete or cement, but canbe filled with insulation, rebar, air, earth, and/or temporary fillingmaterial.

FIG. 12 shows an exemplary external joint filler or connector 60. Theexternal joint connector includes both a male engagement portion 62 anda female engagement portion 64. The male engagement portion 62 and thefemale engagement portion 64 can be of similar configuration andoperation as the previously discussed male and female engagementportions. The external joint connector can be used to fill in gaps topermit an engagement or interconnection, such as engagement of adjacentform elements. FIG. 11 shows an example of an external joint connector60 in operative connection. For example, the open end of a form elementcan be attached or fastened to a closed face of an adjacent form elementusing an external joint connector 60. As can be seen in FIG. 11 anexternal joint connector can extend substantially externally of orbetween adjacent form elements. An external joint connector can employmany features. For example, an external joint connector can be operativeto facilitate a change in direction or the meeting of two form elements.An external joint connector can also be used to adjust the length of awall. External joint connectors can also be used in the creation ofcurved walls. For example, more external joint connectors can be locatedin a first formwork section than in a second formwork section to createa deviation or curvature. One way to form a curvature is to create anunequal number of external joint connectors of the interior vs. theexterior plane of the structure. [Add Drawing(s) from Manual]Additionally, joints of male/female engagements can purposely (orinadvertently) be opened, such as during the assembly or constructionprocess, to gain temporary access to the inside of the formwork. Thestructure of an external joint connector permits its use in thereconnection of previously opened joints. That is, one or more externaljoint connectors can be employed in the re-securing of previously openedjoints.

FIG. 13 shows an exemplary internal joint filler or connector 70. Theinternal joint connector includes two male engagement portions 72, 74.The male engagement portions 72, 74 can be of similar configuration andoperation as the previously discussed male engagement portions. Theinternal joint connector can be used to permit engagement, such asengagement of adjacent form elements. FIG. 14 shows an example of aninternal joint connector 70 in operative connection. For example, aclosed face of a first form element 10 can be engaged, attached,fastened, or operatively connected to a closed face of an adjacentsecond form element 10 using an internal joint connector 70 resulting ina double walled portion 76. As can be seen in FIG. 14 an internal jointconnector can remain substantially internal of or enclosed betweenadjacent form elements. In comparison with an external joint connector60 an internal joint connector 70 can extend a lesser extent. Aninternal joint connector employs many features. For example, an internaljoint connector is operative to connect two adjacent female engagementportions, such as when rotation of form elements or a change in assemblydirection is required.

The exemplary joint connectors 60, 70 make possible many procedures,such as the unzipping of a wall section for access to interiorreinforcement; the repair of a joint; the increasing of a wall lengthsection; the creation of deviations or curvatures, the joining ofsimilar sex components; the easier corner installation of rebar; theerection of wall sections when weather is not optimal or wall sectionsare very long; and the resecuring of previously opened joints.

Form elements can also be of elongated shape. FIG. 15 shows an exemplaryform element 80 of elongated octagonal shape. The form element 80 can beelongated in cross section and longitudinal direction. An elongated formelement 80 can be substantially equal to twice the (cross sectional)thickness of previously discussed (regular) form elements 10. That is,an elongated form element 80 can be substantially twice as wide in crosssection as a form element 10. A comparison of an elongated form element80 with the outline of two form elements 10 is shown in FIG. 16. FIG. 16shows a comparison of an octagonal elongated form element with theoutline of two octagonal (regular) form elements. A formwork assemblycan include both regular form elements and elongated form elements. Itshould be understood that an elongated form element can be a multiple oftwo regular form elements.

Elongated form element 80 also includes female portions 82. A leading orback wall 84 extends opposite an open face 86. The leading wall 84 alsoincludes female portions (82). As shown in FIG. 16, the leading wall 84has a length substantially equal to the length of two faces of formelement 10 plus the length of the gap there between (e.g., the length ofa previously discussed wall panel, e.g., panel 22).

Of course elongated form elements can be of greater or lesser thicknessthan shown in FIG. 15. For example, an elongated form element can betriple the thickness of (regular) form elements 10. Additionally, anelongated form element can be one and a half times the thickness of formelements 10. That is, an elongated form element can be of an integer,fraction, or particular size relative to other form elements to enable acompleted formwork to meet a particular design profile. Use of anelongated form element can permit a reduction in the number formelements needed in a formwork assembly. Thus, use of an elongated formelement can result in cost savings of assembly time. An elongated formelement can also be used to ensure a coordination of corner aesthetics.A strong corner section can be obtained with use of elongated formelements.

FIG. 17 shows an angled view of a cut away portion of a formworkarrangement 88 having form elements 87, elongated form elements 89, andother formwork components, such as wall panels and corner panels,resulting in substantially flat interior and exterior wall surfaces 83,85.

FIG. 18 shows a portion or section of a formwork 90 including formelements 10, elongated form elements 80, external joint connectors 60,and internal joint connectors 70. The arrangement can provide a strongcorner section, especially as the wall system increases.

FIG. 19 shows a buck panel 92 adapted for engagement with a form element10. FIG. 20 shows a buck panel 94 adapted for engagement with anelongated form element 80 or with two form elements 10. The buck panel92 includes a pair of male engagement portions 96. The buck panel 94includes a pair of male engagement portions 97. A buck panel is adaptedto close an open side of a form element. In such a closure, the buckmale portions can mate with the form element female portions nearest theopening. A buck panel can also be attached to other form element walls.For example, a buck panel can be placed adjacent the back wall (e.g.,the wall opposite the open side) of a form element 10. In such aplacement the buck panel would enclose the back wall and the two wallsadjacent to the back wall. Buck panels can be configured in varioussizes for use with form elements 10 and elongated form elements 80. Abuck panel can also include female engagement portions adapted toreceive corresponding male engagement portions, such as form elementmale engagement portions or other formwork component male engagementportions. The buck panel 92 of FIG. 19 includes a pair of femaleengagement portions 98. The buck panel 94 of FIG. 20 includes two pairof female engagement portions 99. A buck panel can also be perforated toallow concrete flow when positioned.

FIGS. 21-24 show various cut away portions of buck panels 112, 114, 116,118 connected to respective form elements 122, 124, 126, 128. Aspreviously discussed, buck panels can be configured in various sizes foruse with various sized form elements and elongated form elements.

To permit ease of formwork construction, the components of the formworkcan all use the same type of male and female engagement portions. Thatis, the male engagement portions of the form elements, wall panels,corner panels, external joint connectors, and internal joint connectorscan be of the same configuration or shape. Likewise, the form elements,wall panels, corner panels, external joint connectors, and internaljoint connectors can have female portions of the same configurationwhich are operative to engagingly receive the respective matching maleengagement portions.

Certain formwork arrangements can be without a female engagement portionat every possible female location of a form element. For example,certain vertices in an octagonal form element, which are deemedunnecessary for engagement purposes, can omit a female portion. That is,as shown in FIG. 25 two adjacent faces 136 of a form element 130adjacent an apex or vertex 132 can be joined absent a female portion134. Likewise, an elongated form element 138 can have one or more femaleportions 137 absent from a wall 139 thereof, as shown in FIG. 26. Stillother arrangements with alternative female portions can be used. Forexample, a female portion can remain on a form element but the entrancethereto can be closed to a male portion. That is, adjacent walls of aform element can be joined in closing a female portion and preventingengagement with an outside male portion.

FIG. 27 shows two adjacent walls 142 of a form element 140 joined inclosing a female portion 144 (or forming a closed female portion) andpreventing engagement with an outside male portion. In FIG. 27 femaleportion material is reoriented to achieve the closure. The closed femaleportion is operative to receive a male portion from the interior of theform element. FIG. 28 shows a closed female portion 146 of a formelement 148 in which additional material has been used in the closure. Afiller strip can also be used to close a female portion. The closedfemale portion (146) of FIG. 28 is not operative to receive any maleportion. Likewise, a wall or vertex of an elongated form element,instead of having an open female portion thereat, can have the femaleportion closed or absent. FIGS. 29-31 show examples of female portions352 being either absent or closed on a wall 354 and/or at a vertex 356of an elongated form element 350. The closure or absence of one or morefemale portions can be useful in producing a substantially smooth apexor wall, in easing a specific assembly process, and in reducingmaterials and costs. FIG. 29 shows a closed female portion of anelongated form element in a manner similar to FIG. 27. FIG. 30 shows aclosed female portion of an elongated form element in a manner similarto FIG. 28. FIG. 31 shows closed and absent female portions associatedwith an elongated form element. Female portions can also be closed foraesthetic reasons. For example, an exemplary embodiment can have femaleportions closed at opposite corners but not along the engagement sideswhere a flat wall panel or a corner panel can be engaged.

FIG. 32 and FIG. 33 are arranged adjacent each other to show acomparison of respective similar wall panels 101, 102. FIGS. 32-33 showthat wall panels 101, 102 can be of similar configuration yet havedifferent lengths. Wall panel 102 has a cross sectional length greaterthan that of wall panel 101. A formwork can use wall panels of differentlengths, especially when both form elements and elongated form elementsare involved. Wall panels can also be of similar configuration yet havedifferent longitudinal (e.g., vertical) lengths.

FIGS. 34-35 show wall panels with alternative male engagement portionconfigurations. In FIG. 34 a first male engagement portion 111 has twofins while a second male engagement portion 113 has a single fin. InFIG. 35 each male engagement portion 115, 117 has a single fin, witheach fin extending inward toward the other fin. Of course otheralternative wall panel configurations can be used. For example, a wallpanel can have each male engagement portion with only one (single) fin,with the first fin extending outward away from the second fin, and thesecond fin extending inward toward the first fin.

FIGS. 36-39 show additional panel arrangements that can be used when lowstrength formwork operations are permitted. For example, the panels ofFIGS. 36-39 can be applicable with a formwork when the panels are notplaced adjacent to poured concrete. These panels can also be used intesting or pre-viewing an assembly. That is, the panels of FIGS. 36-39can be temporarily installed and then later removed.

FIGS. 36 and 37 show comparison examples of different sized wall panels103, 104. Wall panel 103 has a cross sectional length shorter than thatof wall panel 104. FIGS. 38 and 39 show comparison examples of differentsized corner panels 106, 108. Corner panel 106 is of a greater dimensionthan that of corner panel 108. FIGS. 36-39 also show a male engagementportion 107, 109 of an alternative configuration. The male engagementportion 109 protrudes in a manner opposite of the male engagementportion 107. These male portions are configured to engage only one sideof the previously discussed T-shaped female portions. Thus, these maleportions can provide less engaging contact then the previously discussedmale portions. Alternatively, these male portions can be used withfemale portions of other configurations, such as a female portion havingonly one engagement side. For example, these male portions can have afin of a L-shaped configuration. These male portions can also be of agreater length than shown. A female engagement portion can also have analternative configuration (e.g., L-shape) to correspond to or match aL-shaped male fin.

As previously discussed, a form element can have various shapes in crosssection. Form element walls can be substantially of equal length andpositioned at substantially equal angles forming a substantiallyC-shaped cross section. In other exemplary embodiments a form elementcan have walls not of substantially equal length and positioned not atsubstantially equal angles. Form elements can also be without an openend, be circular, or be O-shaped. For example, an octagonal form elementhaving eight walls without an open face, such as shown in FIG. 40, canalso be used in alternative embodiments. The form element 100 of FIG. 40has all sides or faces closed. That is, the form element includes femaleengagement portions but lacks an open face and male engagement portions.A formwork arrangement including a form element without an open face canbe useful in forming a column (e.g., hollow or solid).

The form elements and panels can include apertures to permit fluidcommunication between adjacent chambers in the interior of a formwork.An example of formwork components that use apertures is shown in U.S.Pat. No. 5,216,863 the disclosure of which is incorporated herein byreference. The formwork components can be interconnected so thatconcrete is permitted to freely flow through apertures and into adjacentchambers. FIGS. 41-55 show examples of form elements having variousaperture arrangements, including apertures 110, on the form element wallportions. As shown, both regular and elongated form elements can includeapertures. FIG. 48 shows a form element without apertures. FIG. 55 showsa form element with each face having apertures 110 associated therewith.

Apertures can also be arranged to permit concrete to flow into thespaces or chambers intermediate form elements 10, 80. For example, thecross-sectional triangular open area or channel 24 shown in FIG. 7 canhave access to concrete via flow apertures in one or more form elementsor units.

It should also be understood that apertures can be of various sizesand/or flow areas. Apertures can also be of various cross sectionalshapes, such as circular, oval, and rectangular. The apertures can havepredetermined diameters or flow areas to permit a predetermined amountof concrete to flow therethrough. The same form element can havedifferent sized apertures of different shapes.

An assembled formwork or frame is adapted to retain poured concrete. Thehardened concrete can result in a wall formed of a number of fusedconcrete columns. The concrete wall can become integral or fused withthe formwork frame. The hardened concrete wall can include the formwork.Thus, the exposed exterior portions of the wall can comprise theformwork material. That is, the concrete can be surrounded by andprotected by the formwork material.

Thus, it is the formwork material that can be subject to the exteriorcircumstances, such as the weather.

Furthermore, reinforcement members such as rebar can be placed throughconcrete flow apertures to provide additional structural integrity orstrength. Additionally, reinforcement members such as rebar can usedifferent sized other apertures or perforations for their support. Suchperforations can necessarily be operative to not permit concrete to flowtherethrough. That is, such perforations can be primarily designed toachieve a close fit with the rebar. Thus, concrete can or cannot bepermitted to seep through such rebar perforations. Additionally,apertures can be arranged to permit the insertion of cable therethrough.For example, reinforcement cabling can be used with cylindricalstructure, such as circular tanks. Furthermore, glass fibers and/ormetal fibers can be used in place of rebar. Structure which can serve asimilar functionality as rebar can be used.

Also, apertures or perforations can be provided on exterior componentsof a formwork assembly. For example, a form element, wall panel, cornerpanel, and/or buck panel can include concrete flow perforations topermit a predetermined amount of concrete to flow therethrough to theexterior (or interior) of the formwork. Such exposed concrete can beused to attach other structures, such as a finish, to the concrete wall.For example, bricks, block, stucco, siding, drywall, wood, paneling,advertising, and/or other material can be attached to or bonded with thewall by associating with the exposed concrete.

Additionally, a second formwork can be attached to an adjacent firstformwork by using exterior (or interior) concrete flow perforations inat least one of the formworks. Thus, individual formwork arrangementscan be attached or fixed to each other with concrete from passingthrough concrete flow perforations.

Furthermore, multiple individual formwork wall sections, which can beadjacent and parallel to each other, can be linked side by side tocreate a very thick wall section. Thus, a concrete wall can be formed ofseveral thicknesses, such as two or more times the normal thickness. Forexample, a four-wide wall thickness in the running direction can be usedto increase strength and/or horizontal surface area.

The material of a formwork of the present invention can include knownformwork materials. Additionally, a formwork can include a plastic orvinyl, such as polyvinylchloride (“PVC”). For example, in an exemplaryembodiment, all of the formwork components, such as form elements,panels, and connectors, can comprise PVC. It should also be understoodthat a formwork can use non-PVC polymers, such as nanoclay PP,industrially recycled thermoplastic polymers, etc. Furthermore, formworkcomponents can include selective metal components, which can provideadditional strength. Metal can be incorporated or embedded in a formworkcomponent.

FIGS. 56-59 show examples of formwork sections containing insulation. Aformwork of the present invention permits usage with a variety ofinsulation types and forms. For example, applied insulation can comprisesegments, blocks, slurry, blown-in particles, etc. FIG. 56 shows aformwork arrangement 141 with insulation 143, 145. Insulation is shownadjacent one (exterior or interior) side of a formwork section.Insulation can be in both a form element chamber portion 147 and atriangular portion 149 adjacent a wall panel 151. Insulation can also bein a chamber portion that has apertures 153 associated therewith. FIG.57 shows a formwork arrangement 155 with insulation 157 in form elementchamber portions. The insulation is shown on a side of center-positionedrebar. Insulation can be located on both sides of rebar. Otherinsulation arrangements can have entire form elements filled withinsulation. Further insulation arrangements can have rebar extendingthrough insulation.

FIGS. 58-59 show examples of formwork sections containing alternativeinsulation arrangements. The insulation can be comprised of blocks orsections. One or more blocks of insulation can be attached usinginterengaging projections and recesses in a LEGO® block type ofattachment arrangement. FIG. 58 shows a formwork arrangement 150 withinsulation blocks 152, 154. The attachment arrangement permits a secondblock 154 to be engaged and aligned with a first block 152. Aninsulation block can have a male portion and a female portion. FIG. 58shows a male portion including a projection 156 and a female portionincluding a projection receiving recess or opening 158. The maleprojection is adapted to be received in the female opening. Formworkapertures 159 are also shown. Corresponding male and female portions canbe of various shapes and sizes. The male projection and a female openingcan permit adjacent insulation blocks to directly contact and abut eachother, such as in FIG. 58.

FIG. 59 shows a formwork arrangement 160 with insulation blocks 162,163, 164. The attachment arrangement permits insulation blocks to beengaged and aligned. FIG. 59 shows a block male portion including aprojection 166 and a block female portion including a projectionreceiving opening 168. A male projection and a female opening can bealigned with a formwork aperture or opening 169, e.g., a form elementaperture, so that the male projection 166 extends through the aperture169 while in engagement or connection with the female opening 168, suchas in FIG. 59. That is, a male projection 166 and a female opening 168can permit a form element wall 165, or some other formwork componentportion, to be located therebetween while in engagement with each other.Hence, a form element aperture 169 can assist in supporting and/oraligning insulation sections. As shown in FIGS. 58-59, insulationsegments can be of a size which allows them to be positioned between orinterior of reinforcement members 170, 172 such as rebar. As seen inFIG. 59, concrete can be placed between the insulation and an exterioror side of a form element. That is, the insulation arrangement permitsconcrete to be located in contact with the rebar.

A formwork can include block type insulation segments at a center orinterior portion thereof, as shown in FIGS. 58-59, and other forms ofinsulation at exterior portions thereof Alternatively, block typeinsulation segments can be used at exterior portions of a formwork. Suchinsulation can have interengaging projections and recesses or can haveother devices for holding such blocks in position. Block insulation atformwork exterior portions can be engageable with male projections onwall panels or corner panels. Thus, block insulation at formworkexterior portions can have female portions but lack male portions.Contrarily, block insulation at formwork exterior portions can beengageable with female projections on wall panels or corner panels.

Thus, block insulation at formwork exterior portions can have maleportions but lack female portions. The insulation can also bepre-installed on the panels before the panels are attached to theformwork. The male and female portions can permit insulation segments tobe connected to each other. For example, a male projection can beoperative to be received in a female opening with a snap fit or lockingconnection.

Instead of a flat wall formwork arrangement, a curved or circularformwork arrangement can also be created by use of the presentinvention. Formwork components can be bent to create formwork curvature.For example, flexing can occur in the engagement fins of a male engagingportion (and in open vertices of a female engaging portion).Additionally, a formwork curvature can be created by providing apredetermined slop or play in the engagement of the male and femaleportions. In exemplary embodiments, curves can be formed using onlytolerances and normal joint flex with formwork internal radii rangingfrom two inches to fifty feet. Of course additional angles of curvaturecan be enabled with use of other male and female play tolerances. FIG.60 shows an example of formwork curvature 174 permitted by play in theengagement of male and female portions. A straight shadow line is shownfor comparison.

Other formwork curvature arrangements can be provided by using fewerconnectors in the interior joints than in the outer joints. Further, thesize or dimensions of formwork components can be adjusted to achieveeven more curvature arrangements. FIG. 61 shows an example of formworkcurvature 176 permitted by use of external joint connectors 178. Astraight shadow line 177 is shown for comparison. Other curvaturearrangements are also available. For example, a wall can be comprisedsolely of engaged external joint connectors, with curvature thereofcreated by play in the engagement of male and female portions.

The formwork components can be assembled using mating of correspondingmale and female portions to form a predetermined formwork profile.Examples of different assembly stages are shown in the various drawings.

Furthermore, formwork components can include male and/or female portionsthat permit a formwork to attach to other non-formwork structure. Forexample, trim, molding, window, door bucks, service raceways, piping,supports, or ceiling related structure can be attached to a formwork viamale and/or female engagements. A female (or male) component of aceiling related structure could be connected to a concrete filledformwork by fasteningly engaging with a male (or female) component ofthe formwork.

The formwork of exemplary embodiments can be used in an agriculturefacility, such as a livestock barn. For example, an agriculture facilitycan have a need of a structure capable of storing agriculture feed orwaste in the form of liquid, slurry, and/or solid. The waste cancomprise livestock's manure products. The formwork of certainembodiments of the present invention is suited for use with agriculturematerial. The material and arrangement of a formwork are capable tostructurally retain and provide chemical resistance to agriculturematerial such as waste products. A concrete hardened formworkarrangement also permits easy cleanup or removal of waste from theholding structure. FIG. 62 shows such an agriculture facility 180including a barn 186. A cut away sectional view of a holding structure182 containing agriculture material (e.g., feed or waste) 184 is alsoshown. Both the walls and floor of the holding structure can be made ofconcrete formwork arrangements of the present invention.

Another agriculture facility can require a storage area for vegetable orcrop products. For example, in crop storage the avoidance of a damphumid environment can be desirable. The formwork of exemplaryembodiments can include apertures or openings on an exterior portionthereof to provide entry and drainage of fluid for environmental controlof a storage area.

The apertures can be provided to achieve ventilation for a storage area.For example, apertures can permit circulation of a fluid, such as air,in providing a relatively dry environment. The use of apertures forventilation can also permit enhanced temperature control of a storagearea. For example, apertures can provide acceptable cooling levels forstored goods. Additionally, other arrangements of a storage structureusing a formwork of the present invention can include having aperturesextended, such as by hollow tubes, into an interior storage area.

FIG. 63 shows an example of a formwork section 188 having apertures,perforations, or openings 189 on a (interior or exterior) portionthereof Apertures can be in a variety of formwork components, such asform elements or panels (e.g., wall panels). As previously discussed,apertures can be used for a variety of purposes, such an in providingventing or drainage. Apertures can also be used to prevent and/or removehydrostatic pressure acting on a formwork. As previously discussed,apertures can be used as concrete flow perforations to permit apredetermined amount of concrete to flow therethrough to the exterior(or interior) portion of the formwork. Such exposed concrete can be usedto attach other structures, such as a finish (e.g., brick), to theconcrete wall.

FIG. 64 shows a formwork section having a material (e.g., concrete)filled portion 191 and a hollow chamber portion 193. As previouslydiscussed, apertures can be associated with a hollow chamber forventing, drainage, and/or insulation.

Use of a formwork arrangement in combination with a drainage system hasbeen previously discussed. For example, the cross-sectional triangularopen area 24 shown in FIG. 7 can remain devoid of concrete so as to actlike a drainage channel. FIG. 65 also shows an example of a drainagearrangement. Depending on the desired storage arrangement, drainageapertures or perforations can be located in the wall panels and/orcorner panels and/or the form elements. The bottom of a drainage channelcan be in fluid communication with a drainage system. Fluid and/orliquid could (interiorly or exteriorly) enter a drainage channel andthen proceed by gravity toward the drainage system for removal. Forexample, during cool storage of a crop relatively humid air could enterthrough apertures in a wall panel then condense on a closed form elementthen fall to a drainage system. Thus, a formwork arrangement can becombined in a system to selectively remove moisture and controlenvironmental conditions.

FIG. 65 shows an angled view of an exemplary partial arrangement of adrainage system 201 with hollow form elements. A catch drain 203 isshown beneath form elements 205. The catch drain can be sloped or pumpedto assist in removal of liquid. The arrangement of FIG. 65 can be usedto capture fluid from the form elements and/or from an area exterior ofthe form elements. That is, the form elements of FIG. 65 can containconcrete with the exterior space between the filled form elements actingas a longitudinal drain channel to a drain system. A drainage system canalso be arranged to be in fluid communication with perforations informwork panels (e.g., wall panels and/or corner panels). That is,instead of an open exterior space, perforated panels can be used. Forexample note FIG. 63. Furthermore, a drain system need not be directlyunder the form elements.

FIG. 66 shows such an agriculture facility storage arrangement.

FIG. 66 shows an agriculture facility 190 including a building 191. Across sectional top view of the building 191 shows a storage structure192 containing a moisture sensitive crop product 194. The storagestructure 192 can include a concrete formwork wall 195 and an exteriorlayer of hollow form elements 196 located above a drain system. That is,the facility of FIG. 66 can include a concrete filled portion and ahollow chamber portion, such as shown in FIG. 64. The facility of FIG.66 can use a previously discussed drainage system, such as one similarto that shown in FIG. 65. That is, the form elements 196 of FIG. 66 cancorrespond to the form elements 205 of FIG. 65.

Additionally, an exemplary formwork can be adapted for use in a cleaningfacility, such as in a vehicle wash facility. A self spray type of carwash can produce a buildup of dirt from washed vehicles. This dirt canaccumulate on the walls of the car wash. The material and (smooth) flatwall construction of the formwork of exemplary forms of the presentinvention can permit ease of cleaning to maintain an attractive wallappearance. The attractiveness of the wall appearance can further beenhanced with surface treatment and/or the addition of colorant (such asa bright or shiny color or finish) to the wall material. Alternatively,an adhesive-backed graphics layer can be applied to the outer surface toprovide a different aesthetic appearance. A clear, transparent,semi-transparent, or translucent wall material can also be used. FIG. 67shows an example of a vehicle wash facility 200 including a vehicle washbay 202. The wash bay has a concrete wall 204 formed using a previouslydiscussed formwork. A hose 206 and spray nozzle 208 for a self-washfacility are also illustrated. Of course the vehicle wash facility cancomprise a drive-thru facility.

An exemplary embodiment can also comprise a differential elevationextension formwork. For example, a first portion of the formwork canextend in a longitudinal direction further than at least one otherportion of the formwork. Certain structure can require or benefit from a(flat) wall adjoining a (flat) ledge, step, or shelf. The wall canextend in a (vertical) direction further than the ledge. The wall andledge can also be of different thickness. Furthermore, both the wall andledge can be filled with concrete. The ledge can serve various purposes,such as a brick ledge, a supporting structure, storage area, gardenarea, a bench, etc.

FIG. 68 shows an example of a formwork having a differential elevationarrangement 240. A first formwork section 242 continues extending in anelevated direction from a second formwork section 244. The sections 242,244 can share common apertures 246. Thus, concrete can flow through theapertures 246 to adjacent form element chambers 248, 249. The sections242, 244 can extend from a common base location, such as the ground,with the section 242 continuing to extend further (upward) than thesection 244. The relative differences in lengths of the sections 242,244 can vary.

An exemplary embodiment of the present invention permits a formwork withone or more ledges to still have a flat wall configuration. That is,both formwork sections 242, 244 can have flat wall panels (and cornerpanels). Wall panels 250 attached to the upper section form elements 252can rest on form elements 254 of the lower or stepped section 244. Asshown the ledge section 244 can also have flat wall panels 256.

The formwork sections can also contain different types of material.Additionally, one of the formwork sections can be hollow. For example,the ledge section 244 can be closed to fluid communication with theelevated section 242. That is, the sections can be without commonapertures. Thus, concrete can be prevented from entry into the ledgesection, which can remain hollow. Alternatively, certain chambers in aledge section can be hollow while other chambers can contain concrete.For example, every other chamber in a ledge section can be hollow. Thepreviously discussed embodiments regarding formwork componentarrangements, venting, drainage, rebar, and insulation are alsoapplicable to ledge sections.

Other embodiments can include more than one ledge section attached to anelevated section. For example, ledge sections can be located on eachside of an (single) elevated section. Alternatively, elevated sectionscan be located on each side of a (single) ledge section. An arrangementcan also comprise ledge sections located on each side of an elevatedsection, where the ledge sections share a common base but the lower endor level of the elevated section begins at a level above the common baselevel. For example, the bottom end of an elevated section may begin ator near the upper end of a ledge section. Likewise, a ledge section maybe situated intermediate adjacent elevated sections. For example, theledge and elevated sections can all share a common top base, but thelower end of the ledge section not beginning at the common lower base ofthe elevated sections. Hence, a hollow or tunnel-like arrangement can beformed. Other arrangements can include each of the elevated and ledgesections sharing a common lower base. A ledge section can also belocated at an elevation above another ledge section. Furthermore, theledge sections themselves can be viewed elevated sections with theaddition of more ledges sections. For example, a formwork can take theconfiguration of a plurality of steps.

FIG. 69 shows another example of a formwork having a differentialelevation arrangement 260. The arrangement permits the use of extendedwall panels 258. Insulation 262 can also be used.

Other embodiments of a formwork structure can also be used inapplications other than those previously described. A formwork of thepresent invention is adapted for use in many diverse structures. Suchapplications and/or structures can include (but are not limited to)clean area environments, shelters (e.g., bunkers), vaults, highwaydividers, barns, storage facilities, light factories, food handlingfacilities, warehouses, pools, residential structures, retaining walls,sound barriers, parking garages, storage of radioactive materials, etc.A formwork can have wall surface characteristics that allow ease andthoroughness of cleaning. Exemplary forms of the formwork provideresistance to earthquake crumple. The concrete structure produced by aformwork can be used in above ground, below ground, or aqueousconditions.

The usage of apertures in formwork arrangements has been previouslydiscussed. FIGS. 70 and 71 show an exemplary embodiment of hole patterns(or aperture spacings) for a (regular) octagonal form element. The formelement has faces a-g. FIG. 70 corresponds to faces b, d, and f. Face dis shown in FIG. 70. FIG. 71 corresponds to faces a, c, e, and g. Face cis shown in FIG. 71.

FIGS. 72 and 73 show an exemplary embodiment of hole patterns (oraperture spacings) for an elongated octagonal form element. The formelement has faces a-i. FIG. 72 corresponds to faces b, d, f, and h.Faces d and f are shown in FIG. 72. FIG. 73 corresponds to faces a, c,g, and i. Face c is shown in FIG. 73. In FIGS. 70-73 the apertures canbe formed in various procedures, including during or after form elementfabrication, such as by punching. FIGS. 70-73 also show that differentfaces can have different hole patterns.

In exemplary formwork assembly methods an alignment system can be usedto prevent or reduce bowing or bending of a wall portion of theformwork. For example, the bowing can be due to the force of concreteagainst the formwork wall. As shown in FIG. 74, removable saddles 210can be set on a formwork upper wall portion 212. FIG. 75 is a side viewof the arrangement of FIG. 74. The saddles 210 can extend on both sidesof a wall portion. The saddles can rest on and be supported by a wallportion. Saddles can be of various sizes to extend various lengths downa wall. Each saddle can have one or more supporting members 214. Forexample, a saddle can have a supporting member positioned on each sideof a wall portion. The saddles and supporting members can comprise amaterial such as metal, wood, or plastic. The supporting members areadapted to provide support to an alignment device or straighteningdevice.

An alignment device 216, such as a waler, can comprise any elongatedmember capable of providing a restraining force against an expanding orbowing upper wall portion, such as during a concrete pour. An alignmentdevice can be operative to provide or maintain substantial wall portionstraightness or prevent wall collapse. An alignment device can compriseone or more pieces. A piece can comprise a material such as metal orwood. The saddles and the supporting members thereof can be arranged topress alignment devices closely against the wall portion. The saddlesupporting members can match or exceed the exterior dimensions of analignment device to prevent movement thereof away from a wall duringusage. As shown in FIG. 74 a saddle 210 can extend inward from anoutermost edge of the formwork upper wall portion. That is, saddle 210does not have to contact or extend beyond the outermost edge of theupper wall portion. This can be due to the absence or non-use of wallpanels adjacent the location of the saddle.

In other embodiments, an alignment device can have a thinner sectionadjacent its saddle to permit a thicker section to extend toward thewall for contact thereof. That is, an alignment device 221 can have acutout 222 to permit a thicker section 224 thereof to cover the gapdistance created by the thickness or overlap of a saddle 220, such asshown in FIGS. 76 and 77. FIG. 77 is a side view of the arrangement ofFIG. 76. As shown in FIG. 76 a saddle 220 can be used which extendsbeyond an outermost edge of the formwork upper wall portion 226, whichcan comprise a flat wall panel 228. This can be due to the use of acutout 222. Wedges can also be used. For example, a wedge can be usedwith a supporting member to press an alignment device toward the wall.Also, a wedge can be used between (intermediate) an alignment device andthe wall.

In an example, two saddles can be spaced on a wall portion to supporttwo 2×4 wood pieces, with each respective wood piece supported on arespective wall side. The wood pieces limit outward expansion of thewall. Of course use of more than two saddles can be employed to supporta single alignment device. Furthermore, use of more than two saddles canbe employed to support more than one alignment device on a wall side.After the concrete has hardened, the saddles and alignment devices canbe removed.

In use a formwork can be assembled to receive concrete into the formelements or other chambers adjacent to the form elements. As previouslydiscussed, flow apertures can also be used. Additionally, concrete canbe poured before a formwork profile is completed. In this manner aformwork profile can be completed in stages. For example, a firstsection of the formwork profile can contain wet concrete while the nextsection is still being assembled. The use of staged construction canresult in more efficient assembly.

Thus, exemplary embodiments of the invention achieve at least one of theabove stated aspect, eliminate difficulties encountered in the use ofprior systems and method, solve problems, and attain the desirableresults described above.

In the foregoing description certain terms have been used for brevity,clarity, and understanding. However, no unnecessary limitations can beimplied therefrom because such terms are used for descriptive purposesand are intended to be broadly construed. Moreover, the description orillustrations given are by way of examples and the invention is notlimited to the exact details shown or described.

LISTING OF REFERENCE NUMERALS

10 form element 12 vertex 13 interior chamber 14 wall 16 open face 18female engagement portion 20 male engagement portion 21 formworkarrangement 22 wall panel 24 channel area 25 wall panel end 26 maleengagement portion 28 fin 30 corner panel 32 corner panel end 34 maleengagement portion 38 fin 40 flat wall 42 flat wall 44 corner panel 46corner panel end 48 male engagement portion 50 fin 52 flat wall 54 flatwall 56 perforations 57 channel 58 channel 60 external joint connector62 male engagement portion 64 female engagement portion 70 internaljoint connector 72 male engagement portion 74 male engagement portion 76double walled portion 80 elongated form element 82 female engagementportion 83 wall surface 84 leading wall 85 wall surface 86 open face 87form element 88 formwork arrangement 89 elongated form element 90formwork 92 buck panel 94 buck panel 96 male engagement portion 97 maleengagement portion 98 female engagement portion 99 female engagementportion 100 form element 101 wall panel 102 wall panel 103 wall panel104 wall panel 106 corner panel 107 male portion 108 corner panel 109male portion 110 apertures 111 male engagement portion 112 buck panel113 male engagement portion 114 buck panel 115 male engagement portion116 buck panel 117 male engagement portion 118 buck panel 122 formelement 124 form element 126 form element 128 form element 130 formelement 132 apex 134 female portion 136 face 137 female portions 138elongated form element 139 wall 140 form element 141 formwork 142 wall143 insulation 144 closed female portion 145 insulation 146 closedfemale portion 147 chamber 148 form element 149 triangular portion 150formwork 151 wall panel 152 insulation block 153 aperture 154 insulationblock 155 formwork 156 male projection 157 insulation 158 femalereceiving opening 159 formwork aperture 160 formwork 162 insulationblock 163 insulation block 164 insulation block 165 form element wall166 male projection 168 female receiving opening 169 form elementaperture 170 rebar (reinforcing bar) 172 rebar 174 formwork curvature176 formwork curvature 177 shadow line 178 external joint connector 180agriculture facility 182 holding structure 184 agriculture wastes 186barn 188 formwork 189 aperture 190 agriculture facility 191 concretefilled 192 storage structure 193 hollow 194 crop product 195 concreteformwork wall 196 hollow form elements 198 drainage system 200 vehiclewash facility 201 drainage arrangement 202 wash bay 203 drain 204concrete wall 205 form elements 206 hose 208 spray nozzle 210 saddle 212upper wall portion 214 supporting member 216 alignment device 220 saddle221 alignment device 222 cutout 224 thick portion 226 upper wall portion228 wall panel 240 formwork arrangement 242 formwork section 244formwork section 246 aperture 248 chamber 249 chamber 250 wall panel 252form element 254 form element 256 wall panel 258 wall panel 260 formworkarrangement 262 insulation

In the following claims any feature described as a means for performinga function shall be construed as encompassing any means capable ofperforming the recited function, and shall not be limited to thestructures shown herein or mere equivalents.

The invention is not limited to the above embodiments. The claimsfollow.

1. An apparatus comprising: an elongated regular octagonal first tubularform element, wherein the tubular form element includes a tubularboundary of seven adjacent wall faces and one open face, wherein thetubular boundary bounds a longitudinal interior chamber, wherein thetubular form element includes six female engagement portions eachconfigured as a T-shaped slot having a locus of connection to engaginglyreceive a male engagement portion configured as a T-shaped fin alsohaving a locus of connection, wherein each female engagement portionextends into the longitudinal interior chamber from a vertex of adjacentwall faces, wherein each female engagement portion includes an openingat the tubular boundary as the T-shaped slot, wherein, the tubular formelement includes two male engagement portions extending outwardly of thetubular boundary, wherein the two male engagement portions at the openface of the first form element and, are adapted to engage with twofemale engagement portions of a elongated regular octagonal secondtubular form element on any one of five adjacent wall faces having twofemale engagement portions at two vertices of the wall face, wherein,when engaged, the male engagement portions of the first tubular formelement and the female engagement portions of the second tubular formelement identify a relationship of common loci of each connection withplacement of each locus at the vertices of the rectangular octagons ofthe first tubular form element and the second tubular form element,wherein, when engaged, the female engagement portions extend into thelongitudinal interior chamber to permit the internalization of theconnection of the male engagement portion of the first tubular formelement configured as the T-shaped fin and the female engagement portionof the second tubular form element configured as the T-shaped slot toallow external side surfaces of adjacent tubular form elements as wallfaces to lie within a plane for creation of a flat surface arrangement,and wherein the flat surface arrangement is adapted to be created byfemale engagement portions of adjacent form elements engaging an insertpanel at two male engagement portions, also configured as T-shaped finsidentical to the male engagement portions on the first tubular formelement, to form a substantially flat wall surface.
 2. The apparatus ofclaim 1, further comprising an elongated regular octagonal secondtubular form element engaged with the first tubular form element and theinsert panel engaged with both the first tubular form element and thesecond tubular form element to close a triangular area resulting fromthe two octagonal form elements being engaged, wherein the substantiallyflat wall surface is formed by a wall face of the first tubular formelement, the insert panel, and a wall face of the second tubular formelement.
 3. The apparatus of claim 1, wherein the tubular form elementhas apertures in at least one face of the form element.
 4. The apparatusof claim 1, wherein mated multiple tubular form elements are operativeto form a wall structure of the flat surface arrangement.
 5. Theapparatus of claim 4, comprising multiple wall structures, wherein themultiple wall structures form at least one wall of a building.
 6. Theapparatus of claim 4, further comprising insulation, reinforcing bars,and concrete within the multiple wall structures.
 7. The apparatus ofclaim 2, wherein the tubular form elements have apertures in at leastone face of each form element.
 8. The apparatus of claim 2, whereinmated multiple tubular form elements are operative to form a wallstructure.
 9. The apparatus of claim 8, comprising multiple wallstructures, wherein the multiple wall structures form at least one wallof a building.
 10. The apparatus of claim 8, further comprisinginsulation, reinforcing bars, and concrete within the multiple wallstructures.